I need to find out the diameter of the header pipe as it enters the muffler connection for a 2003-04 640 Motard/Adventure or 2005 or 2007 625 Adventure. I don't have one in my possession to measure myself. TIA.

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Here is what I got; at the very end of the header it measures 1.992"
Then up to the widest point of the flange it measures 2.092

Thanks for taking the time to take measurements and picture. That really seals the deal. The Staintune will require an adapter to go from 44mm on the Tenere to 50mm but the Staintune should tuck in and mount up just fine.

Thanks for taking the time to take measurements and picture. That really seals the deal. The Staintune will require an adapter to go from 44mm on the Tenere to 50mm but the Staintune should tuck in and mount up just fine.

Just picked up a 2000 640 Adventure R a couple of months ago. It was supposed to be an easy fix (according to the previous owner) that ended up costing me a fortune and I'm still not done! It has been an adventure just owning this beast and I still haven't ridden the thing yet!

I am hoping there is someone in the SF Bay area (Peninsula or South Bay, Sunnyvale?) that has one of these monsters (any LC4?) I can come see and hear. I have heard that they sound like threshing machines to begin with, but mine seems to sound like a threshing machine full of ball bearings, marbles, wrenches, rocks etc. Please help! I'm in deep. I will post some pics once I get it back together. Thanks and I hope to get out there and ride one of these days and meet a few of you guys.

I live in SF and I've worked on both a 97/98 Adventure 620 EGS-E (the first one with the dual low-mounted pipes),
as well as, the blue and orange 99/2000 Adventure R my friend use to own.
Just from your description and knowing the engine...it sound to me like you might have the bearings from the main shaft bearing dancing around in there.
This bearing is known to lose it outer race that hold the bearing in and when it does go the bearing themselves are free to reek havoc!
Don't ride it or run it very long.
Just check that bearing first by pulling the clutch plate and stator...etc http://www.advrider.com/forums/showthread.php?t=73558
I only lost the race on my 620 LC4, but I kept going and the block actually cracked, destroying the engine!

Just picked up a 2000 640 Adventure R a couple of months ago. It was supposed to be an easy fix (according to the previous owner) that ended up costing me a fortune and I'm still not done! It has been an adventure just owning this beast and I still haven't ridden the thing yet!

I am hoping there is someone in the SF Bay area (Peninsula or South Bay, Sunnyvale?) that has one of these monsters (any LC4?) I can come see and hear. I have heard that they sound like threshing machines to begin with, but mine seems to sound like a threshing machine full of ball bearings, marbles, wrenches, rocks etc. Please help! I'm in deep. I will post some pics once I get it back together. Thanks and I hope to get out there and ride one of these days and meet a few of you guys.

Thanks Geekventure! I was sort of leaning towards that. Only because I couldn't see anything else wrong with it. No worries about running it now as the engine is out and at the shop for repairs. I will call them today and confirm that they checked the Main Shaft Bearing. (I would hope they would!) There were lots of other issues in addition to that noise. Thanks again! Hopefully, I will get the engine back and it will be in good running condition for a while!

I live in SF and I've worked on both a 97/98 Adventure 620 EGS-E (the first one with the dual low-mounted pipes),
as well as, the blue and orange 99/2000 Adventure R my friend use to own.
Just from your description and knowing the engine...it sound to me like you might have the bearings from the main shaft bearing dancing around in there.
This bearing is known to lose it outer race that hold the bearing in and when it does go the bearing themselves are free to reek havoc!
Don't ride it or run it very long.
Just check that bearing first by pulling the clutch plate and stator...etc http://www.advrider.com/forums/showthread.php?t=73558
I only lost the race on my 620 LC4, but I kept going and the block actually cracked, destroying the engine!

I just bought a set of WP43 forks off e-bay for my project. But now a have a few questions as I Google didn't give me an answer.

1. Which models did use this forks, so I can find a appropriate yokes for them (any other than ktm?). These are from 2002 640 ADV (stated by seller)
2. I am also interested in a front axle diameter if anyone has the information

I just bought a set of WP43 forks off e-bay for my project. But now a have a few questions as I Google didn't give me an answer.

1. Which models did use this forks, so I can find a appropriate yokes for them (any other than ktm?). These are from 2002 640 ADV (stated by seller)
2. I am also interested in a front axle diameter if anyone has the information

Thanks in advance!

Here is the picture from e-bay:

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Not sure if they are from a 2002 640adv, as they should have gray tubes, not silver.

Well had my 06 640A just over one yr. The most I have not been on it is 3 weeks. I love it. Perfect for everything I do. Street, trail,daily commute. The only changes from stock are saddle bags and k60 scout tires. Would not change this bike for any other out there. The only thing I would change is having some great trails right out my front door going to my office.

the top clamp is the same for 43 and 48's the lower clamp is what you need to worry about..

but... in the LC4 family the 2000-03 LC4's, SXCs and some earlier Adventures all came with 43 mm triples.. the sxc isnt rubber mounted the others have locks and are dampened

become freindly with KTM talk's part sales microfishe !!

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Thanks for the info. Since wp43 yokes are a bit rare, would it be ok to use a wp48 clamps and machine a collar for the bottom clamp to fit wp43 forks? These forks will go on a bike for gravel rides and some forest trails, no extreme use in mind.

Thanks for the info. Since wp43 yokes are a bit rare, would it be ok to use a wp48 clamps and machine a collar for the bottom clamp to fit wp43 forks? These forks will go on a bike for gravel rides and some forest trails, no extreme use in mind.

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Do the smaller ktms have different steering stem lengths/bearings? I think KTM put the 43s on the whole range of bikes, my friend's 200 exc has them. I'd look around a bit more. Of course, smaller bikes won't have key mount, but it sounds like you may be able to mix an match a 48 top/43 bottom clamp.